Refractory lining composition



Patented Feb. 8, 1949 NT OFFICE REFRACTORY LINING COMPOSITION William C. Cress, Chicago, 111., assignor 'to Harvey, 11]., a corpora- Whiting Corporation tion of Illinois No Drawing. Application February 5, 1945,

Serial No. 576,369

This invention relates to refractory mixtures or cements which are especially adapted for use as refractory linings for metallurgical furnaces such as converters, ladles and the bottoms of electric furnaces. More particularly, it relates to silica refractory mixtures or cements of the ramming type which are rammed to the desired thickness and/or shape by means of a pneumatic hammer and then heated to form the refractory lining.

The refractory converter linings of the prior art have not been entirely satisfactory because they have not been sufficiently resistant to the attack of molten ferrous oxide and molten siliceous slag, and have not been able to withstand for any considerable period of time the deleterious effects of the high operating temperatures of steel melting furnaces. Neither have these linings been sufliciently resistant to abrasion, nor

have they been able to resist breaking apart due to the sudden temperature changes and to the differential expansion from the large and sharp temperature gradient through the wall.

The refractory linings formed from the refractory mixtures of my invention are markedly superior to the prior art linings in all of the foregoing respects and have a service life not heretofore attainable with any of the prior art refractory linings, in so far as I am aware.

The refractory cement of my invention is a ramming mixture comprising a non-plastic, high quality silica material in comminuted' form such as crushed quartziite-ganister, a high quality silica flour and bentonite, preferably of the 'montmorillonite type. A preferred mixture has the following composition by weight:

- Per cent %-inch ganister 50 %-inch ganister 30 140-mesh Ottawa silica flour 14 Western bentonite 6 I have found that the particle size distributions of the materials 'of my ramming mixture must be controlled in order to obtain fairly uniform packings of maximum density, free of large voids. In general, such results are obtained with a mixture wherein from about 50 to 55% thereof is a coarse fraction varying in particle size from inch down to that which will be retained on a 28 mesh screen, about 10 to 12% is an intermediate fraction which will pass through a 28 mesh screen and be retained on a 65 mesh screen, and the balance is a fine fraction which will pass;

8 Claims. (01. 106-68) size distribution has, approximately, a 55% coarse fractioma 10% intermediate fraction and a fine fraction and is obtained from the aforesaid mixture. In this connection it is to be understood that both the and %-inch ganister as obtained. in. the open market have a coarse, intermediate and fine fraction and the approximate average breakdown of each is as follows:

Tyler Standard Scale a t-1 11. 54-111.

On 28 mesh 69 v 47 Through 28 on 65 mesh 14 24 Through 65 mesh. ..do 17 29 .ing of the constituents of the mixture, for the proportions of these constituents maybe-varied somewhat from those set forth in the preferred example. Thus, for example, the bentonite may y aryfrom 4 .to 8%, the silica fiour fr0m 10 to 18% and the balance of the mixture is 'made up of silica ganister which ranges in particle size from amaximum of inch down to fine particles which will pass through a mesh screen.

' I have found that the inch particles in the coarse fraction of :abalanced-particle size distribution in, accordance with the present invention help knit together the successive rammed layers of refractory lining, thereby producing less marked lamination planes. The 'bentonite imparts plastic properties to the non-plastic silica canister and makes a workable mass. The fine silica flour not only adds to the plasticity and working qualities of the mass, making a more flowable mixture on ramming, but since it is purer than silica ganister it makes a more refractory mixture. In addition, silica flour gives the refractory a lower permeability and it reacts more rapidly with the bentonite to produce a solid depending upon the composition of the refractory. mixture and the amount of water used. In gen era], as much water is addeda aslthe'zrefractory mixture will take without pufiing .or flowing when rammed with a pneumatic. hammer. In'most'instances, water in an amount of from about6 /2 to 7 5% of the weight of the other constituents is sufiicient. Collapsible metaliormszarerplaced in the furnace to shape the lining and the material is rammed into place to the desired .thickness, usually from about 4 to 14 inches, with a -.pneumatic.hammer, in accordance with conven- V tional procedures. It is preferredfthat thelining layer-she built up progressively to the desired i-lthickne'ss'by ramming only 1 to 2'inch layersof 1 material. at a 1 time. .JAfter the desired thickness .of lining has been rammed in placeitis dried as V by blowing hotairVthrough the furnacefor about 25.. hours,. then :tpreheated slowly and uniformly .Ior about 4.to.l2 hours below red'heatiand until the whole inside 'of the refractory lining is at red heat, in accordance with standard procedures.

.Duringthe course of theheating of the lining amaterial'the bentonite melts (at 2390 to 2462 F.) and reacts withthesilica flour and the other fine particles of -silica in the mixture to vbond the l larger ganisterparticles together. :i-iihis reaction takes place at temperatures-considerably below the'elevated operating temperatures'of steel melt- .-:ing fur-naces andthebondis developed at a lower temperature than .is possible with .''the prior. art ,ereiractoryliningmixes. ilThe bondis a solid bond and develops in depthrtoanextent notheretofore attainable, not infrequently to some'6 to 8. inches below the=surface .of thelining. -V InVVcontrastjthe V .-.bonds developed .insliningslmaderfrom'oneof the best-bribe; prior artrrefractorymixesi .do.n'otV gen- -V .erallyi extend beyond about. ,1 ;to' .2 inches below Vithe-surface of.-V-the'.li-ning.

.aAt-thesurfaceof the-liningto a depthofabout Vsfz /zetol inch-there .is ayerynense layer which '-.resistsgpenetration .of. slag and metal. back of -this layer-i adepth of. about. 6;to' 7. inches,.the lining is a. thoroughlysintered, rock-like r e- V-.fraetory. a

VThe refractory:lining producedzfronLthe refractorymixture inraccordance. withemy invention e. is capable of withstanding. considerably. higher .-temperatures.wthan ithe .linings heretoiore used eianditliesservice lifathereof is-atleastdouble that of some of theV best of-Vlthe, -.-.prior iart -linings.

.-rFoundry;sladiezliningslmade;fromVmy 'Vmixtures' Vhave given fromlfiveto six weeksi of service, -without.requiringmatching; whereas onei'iflthe .bestof Vthe..prionartiadlediningssubjected toithe same cconditionsgave .a.ser.vice life "of but one week with :patching.

- .The litefractorycmixturenot. my invention may "be .sold in .dry mixtureiormarid beV mulled' with g water. into a rammingrmixture at thejplaceof. use,

,or. it. may -be. sold. in ramming. mixture" .form in hermeticallyasealeddrumsror VcontainersVVto avoid V. lossiotwater.

. VLclaim: V

1-;A-..compositioneadaptertior. use as a re- ;rfractorylining for converters; ladlesian'dithe'likey consisting of a homogeneous mixture 'ofganister;

4 silica flour and bentonite, approximately 50% by weight of said mixture consisting of ganister having a particle size varying from inch to a particle size which will pass through a 28 mesh 5 screen, approximately 30% by weight consistin 1 otganistenhaying a,,partic l e size varying from V A,.inch-fto aparticleisize whicl'nwill pass through a 65 mesh screen. approximately'14%' by weight sbeing the silica flour and approximately 6% by 19 weight being the bentonite.

1 composition adapted for use as a refractoryV..lining Vfor converters, ladles and the like -..-consistinglofaiVhomogeneous mixture of ganister,

silica-flour and bentonite, approximately 80% by lb weight of said mixture consisting of ganister hav- Qing a-particlesize varying from inch to a particle size which will pass through a 65 mesh .-screen,- approximately 14% by weight being the silica flour and approximately 6% by weight being 20,. thebentonite. V

3.;A composition. adapted for. use as a'refrac tory lining for converters, ladies and "the like consisting .of, inhomogeneous admixture, approximately 4m 8% by Weight of bentonite,:approximately 10 to 18% by weightbfsiiicaflciur -andtthebalance silica ganister of aparticle "size varying-from inch to a particle-sizewhichwill ..,pass through a 65mesh screen.

4. A composition adapted for useasarefrac- Vtory lining for converters, ladies and the like -con- V sisting of, in homogeneous admixture," approximately 4 to 8% .by weight of bentonite, approxvin'iaibely V10 to 18% 'byweightof'silicafiour and the balance silica ganisterof aparti'clesize'varying from f 3 inc'hfto "a'particle sizewhich' will passthrough al -65 mesh screen and of-a grain distribution such "that'approximately is retainedon a"28'-'mesh"screen,-approxirnately 10% "passesthrcugh a 28'meshscreen' and is'retained on a- -mesh-screen and approximately-85% *passes through a 65meshscreen.

5. A water-containing "ramming composition for use as a refractory-liningfor convertersla- -diesand the. 'likeg which" composition contains, tbesi'dcs the iwaten 'noiiotherconstituents than solid constituents-whichconsist of a homogene- .ousVmixturetof: ganisterpsilicawfiour-and bentoniteyapproximately 50 %v'by weightcf-saidmixtureaccnsisting of ganisterhaving a particle-size 1' r varying-.irom-ve inch-to a. DE-L'tlCflQVSlZE winch will pass' through a 28' mesh-screen; approximate- ,Vly 39% by weight consisting.viofuganister shaving aparticle-size varyingfrom linchto a particle sizawhichwillpass through a 65 .mesh screen, .-approximately...l4%. by weightflbeing] thefsilica flour and approximately 6%.flby weight being the bentonite.

(ii-A water-containing ramming composition for useas a'refractory lining for-=converters;; la 69 1 dies and the-like which composition contains; be-

sides thewaten no other constituents than solid constituents --wh-ich consist" "of e. -"homogene'ous mixture not ganister, .-.silicai. -fiour and.. bentonite, -;approximately-30-% by weightaof said. mixture consisting .oi? "ganister havingatparticle size varying from-.%.inchto aparticle size which will pass throughVa 65. mesh screen, approximately 141% by weight Zofssaid: mixture being the silica flour and Vapproximately 6% by weight beinglthe bentonite. -'?.VVAwater-contaiining ramming composition I'for.use'as a refractorylining for converters, la- ;dles sand the like,rwhich'.composition'contains, "besides the watery? no "other'nonstituents "than solid constituents which 'consist of, "homogeneous admixture, 'approximately 4 "to "8% I by weight of bentom'te, approximately to 18% by weight of silica flour and the balance silica ganister of a particle size varying from inch to a particle size which will pass through a 65 mesh screen.

8. A water-containing ramming composition for use as a refractory lining for converters, ladies and the like, which composition contains, besides the water, no other constituents than solid constituents which consist of, in homogeneous admixture, approximately 4 to 8% by weight of bentonite, approximately 10 to 18% by weight of silica flour and the balance silica ganister of a particle size varying from inch to a particle size which will pass through a 65 mesh screen and of a grain distribution such that approximately 55% is retained on a 28 mesh screen, approximately 10% passes through a. 28 mesh screen and is retained on a 65 mesh screen and approximately passes through a. mesh screen.

WILLIAM C. CHESS.

REFERENCES CITED The following references are of record in the file of this patent:

UNITED STATES PATENTS 

